Hinged Mattress Foam Channels for Adjustable Bed Articulation
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Solution Overview
Problem
Conventional mattresses for adjustable beds experience wear and tear near joints, leading to reduced lifespan and uneven articulation, as stabilizing structures resist bending and compromise the integrity of the mattress material.
Innovation Solution
The mattress design incorporates multiple flexure points with channels in the support foam layer, allowing for articulation while minimizing wear and tear, featuring channels on both the top and bottom surfaces that act as hinges to facilitate smooth movement and reduce mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If stabilizing and reinforcing structures are added to mattresses to prevent sagging and increase lifespan, then mattress strength and durability are improved, but the mattress resists bending and cannot conform to articulated sections
Solution Approach 1:
The mattress is divided into multiple independent sections that can articulate relative to each other at hinge points. Channels are created in the foam layers at these hinge points to facilitate bending while maintaining structural integrity in non-hinge areas.
Solution Approach 2:
Different regions of the mattress have different structural properties. Hinge points have channels that allow bending, while other regions maintain full foam density and structural support. This localized differentiation allows the mattress to bend where needed while remaining strong where support is required.
2Ease of operation
If mattresses are forced to bend along the joints of the foundation, then articulation is achieved, but wear and tear increases and lifespan is reduced
Solution Approach 1:
Channels are pre-formed in the foam layers at hinge points before the mattress is assembled. These channels prepare the structure to accommodate bending stresses by providing a predetermined path for flexure, preventing random cracking and material failure during articulation.
Solution Approach 2:
The channel structures act as cushioning elements that absorb and distribute bending stresses before they can cause damage to the foam material. The channels provide a stress-relief mechanism that protects the surrounding foam from excessive wear and tear during repeated articulation cycles.
3Device complexity
If conventional foam mattresses are used on articulated foundations, then mattress simplicity and cost-effectiveness are maintained, but the mattresses do not fully conform with articulated sections and experience significant wear
Solution Approach 1:
The foam mattress is segmented with channels at hinge points, creating distinct articulation zones. This segmentation allows the mattress to conform to articulated sections while maintaining the simplicity of a foam construction overall, avoiding the need for complex mechanical components.
Solution Approach 2:
The physical parameters of the foam (density, channel depth, channel width) are optimized to balance flexibility and support. By adjusting these parameters, the mattress achieves adequate conformability to articulated sections while maintaining structural integrity and resisting wear.
Data Source
AI summary
In many aspects, the systems and methods described herein include a mattress having a top sleeping layer disposed on top of a support layer. The support layer includes a polyurethane foam having channels aligned with the joints of the articulated sections of the foundation or frame of the adjustable bedding assembly. When the sections articulate about the joints, the channels allow the overlying top layer to conform to the sections while reducing wear and tear therein.